Extruded fastener and method for making same

ABSTRACT

An extruded integrated fastener assembly comprising a plurality of fasteners cut to length from an extruded length of material. Unwanted areas of material are cut away leaving the individual fasteners, which fasteners are also connected together by an expanse of material that remains. The fastener assembly can be single durometer or double durometer. A profile with retention members and/or leg features are formed in the fasteners for connecting to a predetermined component. The process for manufacturing the extruded integrated fastener assembly includes providing fabrication tooling suitable to cut away the unwanted area between the fasteners. The fasteners are thereby able to be cut to any desired length.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/538,355 filed Jul. 28, 2017. The disclosure of the above applicationis incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to an integrated fastener and process formanufacturing same.

BACKGROUND OF THE INVENTION

Current extruded fasteners, such as extruded push pins and attachmentclips or attachment clip strips, are rather expensive to manufacture.The process for manufacturing can also be time consuming. One commonmethod is molding push pins. In addition, the fasteners do not haveadequate retention. There is also less capability for effectively andefficiently changing the fastener length, when desired. Typicalfasteners are also individual pieces that may become lost easier or beundesirable for certain applications.

Therefore, it is desirable to have an integrated fastener and method formaking same which incorporates fabrication tooling for the integratedfastener to be cut to any desired length.

SUMMARY OF THE INVENTION

The present invention is generally directed to an extruded integratedfastener with at least two fasteners, preferably, push pin fasteners. Acontinuous strip of predetermined profile is extruded. By way ofnon-limiting example, the extrusion includes a wider upper portion whichis integrally formed with a lower depending portion having a pluralityof grippers extending longitudinally along the lower depending portionof the continuous extrusion. Fabrication tooling is provided to form theintegrated fastener. Preferably, to fabricate notches of predeterminedwidth along the longitudinal length of the lower depending portion or“extending portion” to form a series of fasteners (most preferably, pushpins) that are connected only to the wider upper portion, e.g., to gangparts together. The fabrication tooling cuts away the unwanted area oneither side of each fastener. The fasteners can thereby be cut to anypredetermined desired length depending on the application.

The process in accordance with the present invention provides improvedcosts in manufacturing, e.g., about ¼ the cost of conventionalfabrication. The product also has improved retention. And the fastenersare ganged or linked together by a strip of the extruded material.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a convention individual push pin;

FIG. 2 is a front elevation of the push pin of FIG. 1;

FIG. 3 is a perspective view of an extruded integrated fastener assemblybroken along its length to depict that the strip may be any desiredpredetermined length depending on the particular application, inaccordance with the present invention;

FIG. 4 is a front elevation view of the extruded integrated fastenerassembly, in accordance with the present invention;

FIG. 4a is a top plan view of the extruded integrated fastener assemblyof FIG. 4 depicting a plurality of fasteners ganged together, inaccordance with the present invention;

FIG. 5 is a front elevation view of the extruded integrated fastenerassembly in a 90 degree orientation from FIG. 4;

FIG. 5a is a side elevation view of the extruded integrated fastenerassembly of FIGS. 4-5 depicting the plurality of fasteners gangedtogether, in accordance with the present invention;

FIG. 6 is an enlarged front elevation view of the extruded integratedfastener of FIG. 4 illustrating an exemplary single durometer andsubstantially parallel grippers, in accordance with the presentinvention;

FIG. 7 is a front elevation view of an extruded integrated fastenerillustrating an exemplary dual durometer and substantially parallelgripper portions, in accordance with the present invention;

FIG. 8 is a front elevation view of an extruded integrated fastenerillustrating an exemplary single durometer and offset gripper portions,in accordance with the present invention;

FIG. 9 is a front elevation view of an extruded integrated fastenerillustrating an exemplary dual durometer material and offset gripperportions, in accordance with the present invention;

FIG. 10 is a front elevation view of a conventional attachment clip witha retention member corn pressed to a closed or retention position;

FIG. 11 is a front elevation view of the conventional attachment clip ofFIG. 10 overlaid by legs of a fastener in accordance with the presentinvention;

FIG. 12 is a front elevation view of an extruded integrated fastenerassembly depicting a fastener pushed through an exemplary sheet metalslot from one side and retained against the other side of the sheetmetal to prevent the fastener from backing out of the slot, inaccordance with the present invention;

FIG. 13 is a front elevation view of an extruded integrated fastenerassembly depicting a fastener, which includes a hinge area, being pushedin an engagement direction through an exemplary sheet metal slot, inaccordance with the present invention;

FIG. 14 is a front elevation view of the fastener of FIG. 13 with legsof the fastener pushed further in an engagement direction and extendedgenerally outward from the application of force, in accordance with thepresent invention;

FIG. 15, is a front elevation view of an extruded integrated fastenerassembly depicting a fastener including a hinge area and a reverse bowof an upper portion, the fastener depicted being pushed through anexemplary sheet metal slot, in accordance with the present invention;

FIG. 16 is a perspective view of the extruded integrated fastenerassembly of FIG. 15 with the fastener depicted at a resting position,wherein the integrated fastener assembly is broken along its length todepict that the strip may be any desired predetermined length dependingon the particular application, in accordance with the present invention;

FIG. 17 is a perspective view of the extruded integrated fastenerassembly of FIG. 13 with the fastener depicted at a resting position,wherein the integrated fastener assembly is broken along its length todepict that the strip may be any desired predetermined length dependingon the particular application, in accordance with the present invention;and,

FIG. 18 is a side elevation view of an extruded integrated fastenerassembly, wherein the integrated fastener assembly is broken along itslength to depict that the strip may be any desired predetermined lengthdepending on the particular application, in accordance with the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

FIGS. 1-2 depict an example of a conventional individual push pin. Thelarger head 1 is square, but other conventional push pins have round,C-shaped, etc heads. The body is a narrower shaft 2 with teeth 3 orother shaft retaining feature such as circumferential threads.

Referring to FIGS. 3-18 generally, in accordance with the presentinvention there is provided an extruded integrated fastener assembly,e.g., most preferably, push pins, linked together by an expanse ofmaterial, and a process for manufacturing same. It is understood thatthe fastener comprises any predetermined profile suitable for retentionand predetermined properties depending on the particular applicationwithout departure from the scope of the present invention. By way ofnon-limiting example, each extruded integrated fastener assemblyincorporates one or more fastener types which are push pins, attachmentclips, Christmas tree fasteners, pop rivets, push rivets, clipfasteners, or any other suitable fastener and profile, etc and anycombination of fasteners.

Referring more particularly to FIGS. 3-9 generally, in accordance withthe present invention there is provided the extruded integrated fastenerassembly shown generally at 10 including the at least two fasteners 12(e.g., most preferably, push pins of predetermined width, depth, lengthand durometer(s) depending on the particular application) linkedtogether by an expanse of material 14. During fabrication, the extrusionis a continuous piece and the predetermined tooling cuts away theunwanted areas of the fasteners 12, e.g., push pins, most preferablyclip fasteners, forming at least an upper portion 16 and a lowerportion, shown generally at 18. The extruded continuous piece has apredetermined profile depending on the particular application. Thefasteners can be any desired length “L” depending on the particularapplication. The lower portion 18 of the extrusion additionally has atleast one retention member, preferably has a plurality of retentionmembers 20. Most preferably, the retention members 20 are grippers.These grippers 20 can be in parallel rows along the longitudinal lengthof the sides of the fasteners 12 (e.g., see FIGS. 6-7), or, offset fromeach other (e.g., see FIGS. 8-9).

After being extruded, the continuous strip is notched out or otherwisecut to define individual fasteners 12. In particular, the lowerdepending portion of the strip is cut out at predetermined intervals toform gaps, shown generally at 22, in the extrusion. These gaps have apredetermined width “W” that define the space between the lower portions18 of adjacent fasteners 12, and thereby the depth “D” of each fastenerlower portion 18. The predetermined width “W” of the gaps 22 betweenadjacent fasteners 12,12 depends on the particular application. The gaps22 have a height “H” that defines height of the lower portions 18 fromthe underside of the upper portion 16. The predetermined length L andpredetermined depth D of the fasteners 12 depend on the particularapplication. The upper portion 16 of the continuous strip 10 is also cutaway at predetermined intervals to define the distance between the top16 of each fastener 12 and the width of each expanse of material 14 thatchains adjacent fasteners 12 together.

Alternatively, the top portion 16 of the continuous strip is not cut,but rather links the plurality of fasteners 18 together without anarrower expanse of material providing the assembly 10. Thus, theexpanse of material 14 would be a seamless continuous portion of theupper portion 16 when viewed from a top plan view.

The assembly 10 is a single durometer or a dual durometer, depending onthe application.

FIG. 6 depicts the fastener 12 with exemplary single durometer fastenermaterials, e.g., hard material suitable for retention, and substantiallyparallel grippers 20. An inner portion 24 or stem is the same durometeras the grippers 20.

FIG. 7 depicts the fastener 12 with exemplary dual durometer fastenermaterials. The grippers 20 a are preferably thicker than the singledurometer fastener. The durometer of the grippers 20 a is different thanthe inner portion 24. Most preferably, the inner panel 24 of thefastener is a harder durometer material than the grippers 20 a.

FIG. 8 depicts the fastener 12 with exemplary single durometer fastenermaterials, e.g., harder material, which is identical to FIG. 6 exceptthat the fastener inner panel 24 a is longer, and the fastener 12 hasoffset grippers 20 b.

FIG. 9 depicts the fastener 12 with exemplary dual durometer materials,which fastener is identical to FIG. 7 except that the fastener innerpanel 24 a is longer. The grippers 20 c are preferably thicker than thesingle durometer fastener. The durometer of the grippers 20 c isdifferent than the inner portion 24 a. Most preferably, the inner panel24 a of the fastener is a harder durometer material than the grippers 20c.

The process of the present invention provides the extruded integratedfastener with at least two push pins. A continuous strip ofpredetermined profile is extruded. By way of non-limiting example, theextrusion includes a wider upper portion integrally formed with a lowerextending portion with a plurality of grippers along the longitudinalaxis of the continuous extrusion. Fabrication tooling is provided toform the integrated fastener. In particular, to fabricate notches ofpredetermined width along the longitudinal axis of the lower extendingportion to form fasteners that are connected only at the upper portion,e.g., to gang parts together. The fabrication tooling cuts away theunwanted area on either side of each push pin. The pins can thereby becut to any predetermined desired length depending on the application.

The process in accordance with the present invention provides improvedcosts in manufacturing, e.g., at least about ¼ the cost of conventionalfabrication. The product also has improved retention properties. Inaddition, there are no loose pieces since the fasteners are gangedtogether. Another significant advantage is the incorporation of singleor multiple durometers and various retention features.

In use, a final assembly 10 of predetermined length, depending on theapplication, is used, e.g., cut to length suitable for attachment to avehicle part. Each final assembly has at least one fastener, preferably,at least two fasteners, most preferably, more than two fasteners.

FIG. 10 illustrates another prior art fastener 50 that has a depressiblepart 52 that compresses to a closed position for retention.

FIG. 11 illustrates legs compressible legs 102,102 of an extrudedintegrated fastener assembly, according to the present invention,overlaid over the conventional fastener 50, for illustration.

Referring now more particularly to FIGS. 12-18 generally, the extrudedintegrated fastener assembly indicated generally at 100 includes atleast two fasteners shown generally at 104, e.g., preferably, attachmentclips, forming the lower portion of the assembly 100. The legs 102 ofeach include a step portion 106. After the legs 102 are pushed from oneside of a part 101 through a slot 108, sheet metal slot formed in thepart, the legs 102 expand outward and each step portion 106 retains thelegs 102 on the within the slot 108. An upper portion 110 of theassembly is a continuous piece that links the fasteners 104 together.The upper portion 110 includes opposing side legs 112,114 that contactthe top of the sheet, e.g., metal sheet in which the slot is formed 108.Each fastener 104 is cut to a predetermined width, length and depth.

Generally, the process of manufacturing is substantially identical asdescribed previously, except that the fastener has legs 102 that areoperably formed (or operably cut out) and have no grippers. The processfor forming the assembly 100 is identical as set forth previously,wherein, in general, the continuous strip with predetermined profile isextruded and then cut out in the lower portion to define the distancebetween each individual fastener 104 (and the length of each fastener104 in the longitudinal direction).

Referring more particularly to FIGS. 13-14 generally, the assembly 100is substantially identical as shown and described previously, exceptthat the opposing legs 212,214 are longer legs for built-ininterference, and, a hinge 216, preferably, a small longitudinal recessor channel or notch, is also formed in the lower surface of the upperportion 110 between the legs 102,102. This hinge 216 predicts the flexpoint. The upper portion 110 of the assembly is a continuous piece thatlinks the fasteners 104 together. The legs 102,102 are preferably longerto coordinate with the longer 212,214. The opposing side legs 212,214contact the top of the sheet, e.g., metal sheet in which a slot isformed 108. The opposing legs 212,214 are longer legs (e.g., longer thanFIG. 12, for example) for built-in interference. The fastener 104 ispushed through the slot 108 and a downward force “F” on the uppersurface of the upper portion 110 opposite the hinge 216 causes the legsto push out further in an engagement direction. Each step portion 106retains the legs 102 within the slot 108. Each fastener 104 is cut to apredetermined width. The process for forming the assembly is identicalas set forth previously, wherein, in general, the continuous strip withpredetermined profile is extruded and then cut out in the lower portionto define the distance between each individual fastener 104 (and thelength of each fastener 104 in the longitudinal direction).

Referring to FIGS. 15-16 generally, the extruded integrated fastenerassembly indicated generally at 100 includes at least two fastenersshown generally at 104, e.g., attachment clips, forming the lowerportion of the assembly 100. Legs 102 of each include a step portion106. A hinge 216, preferably, a small longitudinal axis recess orchannel or notch, is formed in the lower surface of an upper portion 310between the legs 212,214. This hinge 216 predicts the flex point. Theupper portion 310 has a reverse blow to assist the fastener 104 toinsert easier. The upper portion 310 of the assembly is a continuouspiece that links the fasteners 104 together. The upper portion 310 alsoincludes opposing side legs 212,214 that contact the top of the sheet,e.g., metal sheet in which a slot is formed 108. The opposing legs312,314 are longer legs for built-in interference. Each fastener 104 ispushed through a respective slot 108 and a downward force “F” on theupper surface of the upper portion 310 opposite the hinge 216 causes thelegs to push out further in an engagement direction. FIG. 15 depicts thelegs 102,102 compressed as the fastener 104 is pushed through the slot108. Each step portion 106 retains the legs 102,102 within the slot 108.Each fastener 104 is cut to a predetermined width. Preferably, the legs102,102 to accommodate the reverse bow, than the substantially flatupper portion. The process for forming the assembly is identical as setforth previously, wherein, in general, the continuous strip withpredetermined profile is extruded and then cut out in the lower portionto define the distance between each individual fastener 104 (and thelength of each fastener 304 in the longitudinal direction).

In use, a final assembly 10,100 of predetermined length, depending onthe application, is used, e.g., cut to length suitable for attachment toa vehicle part. Each final assembly has at least one fastener,preferably, at least two fasteners, most preferably, more than twofasteners (e.g., see FIG. 18 broken along the length indicating that thefinal assembly can be any predetermined length suitable for theapplication.

It is understood that the legs 112,114,212,214,102,104 described orshown throughout the application can be any predetermined lengths andcombinations of lengths depending on the particular applications withoutdeparture from the scope of the present invention. By way ofnon-limiting example, when the opposing legs 212,214 of the upperportion are longer, the corresponding legs 102,102 of the fastener areoperably longer.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the essence of the inventionare intended to be within the scope of the invention. Such variationsare not to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. An extruded integrated fastener assembly,comprising: a continuous strip of extruded material incorporating aplurality of fasteners of predetermined length cut into the continuousstrip in the same orientation relative to a longitudinal axis of thecontinuous strip, said plurality of fasteners having a generallyrectangular cross section; a plurality of retention members located onboth sides of each of the plurality of fasteners extending the width ofboth sides to retain each fastener with respect to an aperture of acomponent; and an upper portion of the continuous strip linking adjacentfasteners.
 2. The extruded integrated fastener assembly of claim 1,wherein the plurality of fasteners are extruded to have a predeterminedprofile for connection to a predetermined component with each of saidplurality of fasteners operably connecting to a corresponding attachmentfeature of said component.
 3. The extruded integrated fastener assemblyof claim 1, wherein the plurality of retention members are grippers. 4.The extruded integrated fastener assembly of claim 3, wherein thegrippers are arranged in parallel columns.
 5. The extruded integratedfastener assembly of claim 3, wherein the grippers have an offsetarrangement.
 6. The extruded integrated fastener assembly of claim 1,wherein the assembly is formed of a single durometer material.
 7. Theextruded integrated fastener assembly of claim 1, wherein the assemblyis formed of a dual durometer material.
 8. The extruded integratedfastener assembly of claim 7, wherein the assembly is formed of a dualdurometer material, and the softer material forms a plurality ofretention members.
 9. The extruded integrated fastener assembly claim 1,further comprising legs retained in a sheet metal aperture, wherein thelegs expand outward as a downward force is applied to the fastener in anengagement direction.
 10. The extruded integrated fastener assemblyclaim 1, further comprising a hinge to predict a flex point forinstallation of the plurality of fasteners to a component.
 11. Theextruded integrated fastener assembly claim 1, further comprising anupper portion with a reverse bow to assist insertion of the plurality offasteners into a component.
 12. The extruded integrated fastenerassembly claim 1, wherein the plurality of fasteners is a push pin or anattachment clip.
 13. The extruded integrated fastener assembly claim 1,wherein the plurality of fasteners are each an attachment clip withcompressible ramped legs to prevent the fastener in an installedposition from backing out of an aperture formed in a component to whichthe plurality of fasteners are installed.
 14. A method of making anextruded integrated fastener assembly, comprising: providing anextruder; providing a fabrication tool; extruding at least one materialof predetermined durometer forming a continuous strip of predeterminedprofile; cutting away predetermined areas of the continuous strip withthe fabrication tool to form a plurality of fasteners of predeterminedlength; wherein the plurality of fasteners are connected together by anexpanse of material that is not cut away by the fabrication tool. 15.The method of claim 14, wherein said plurality of fasteners are pushpins with a plurality of grippers extending horizontally the depth ofboth sides of said push pin.
 16. The method of claim 14, furthercomprising co-extruding a softer durometer material to form a pluralityof retention members.